Micro-fuel cell power devices

Abstract

Coupling miniature liquid fueled fuel cells with portable electrical devices, with or without rechargeable batteries, lead to new appliance configurations: charging holster, piggyback charger, fuel cell integral with rechargeable battery, fuel cell with voltage regulating electronics, supplying fuel through a tube with a valve or pump, and supplying power though an electric cable between the fuel cell and the electronic device and the fuel cell power pack having independent communication and functions from the portable electrical devices. In all of these configurations there may be a window showing the fuel level of a disposable fuel ampoule or refillable fuel tank. Fuel is distributed through disposable fuel ampoules in blister packages, or refueling bottles. Adjustable moisture and thermal internal insulation allows fuel cells to run at elevated temperatures. These design features permit greater performance, workability, and convenience to the user of these portable electronics. Additionally, these MICRO-FUEL CELL arrays, which pack more energy into a small space, may be mass produced on a plastic film in a reel-to-reel process.

We claim:  
     
       1. An apparatus having a power source for a battery powered device comprising an energy source, a fuel cell array consisting of at least one rechargeable fuel cell array sub-assembly having a plastic web comprising a patterned porous plastic substrate, electrolyte coating on the substrate, diffusion membrane, and gas manifolds for receiving fuel from the energy source and converting to power supply for the device, a thermal insulation and gas diffusion mat positioned on the fuel cell array, the gas diffusion mat having a water distribution matrix for removing and/or supplying water to the fuel cell array, and fuel manifolds in the fuel cell array, and a holder for receiving the battery powered device, the energy source, the thermal insulation and gas diffusion mat, and the fuel cell array. 
     
     
       2. The apparatus of claim  1 , wherein the holder is of a plastic material. 
     
     
       3. The apparatus of claim  1 , wherein the energy source is a fuel tank. 
     
     
       4. The apparatus of claim  3 , wherein the fuel tank contains fuel that has a 1:1 molecular ratio of methanol to water. 
     
     
       5. The apparatus of claim  3 , wherein the fuel tank is replaceable. 
     
     
       6. The apparatus of claim  3 , further comprising a cavity in the holder for receiving the fuel tank. 
     
     
       7. The apparatus of claim  3 , further comprising a fuel level indicator window in the holder for viewing the level of fuel in the fuel tank. 
     
     
       8. The apparatus of claim  1 , further comprising a location in the holder for locating the portable battery charger and battery powered device. 
     
     
       9. The apparatus of claim  1 , further comprising power connecting electronics in the holder. 
     
     
       10. The apparatus of claim  1 , further comprising a clip on the holder for attaching the holder to a user's clothing. 
     
     
       11. The apparatus of claim  1 , further comprising a rachet mechanism for releasably securing the battery powered device to the holder. 
     
     
       12. The apparatus of claim  1 , wherein the diffusion mat has a thickness that varies across the fuel cell array. 
     
     
       13. The apparatus of claim  1 , further comprising a cover for covering the holder. 
     
     
       14. The apparatus of claim  1 , wherein the fuel cell array is a surface replica fuel cell power source. 
     
     
       15. The apparatus of claim  5 , further comprising a package having a plurality of fuel tanks for replacing spent fuel tanks. 
     
     
       16. The apparatus of claim  3 , wherein the fuel tank contains fuel having a hydrogen bearing compound. 
     
     
       17. The apparatus of claim  16 , wherein the fuel is selected from a group consisting of alcohol and hydrocarbon bearing compounds. 
     
     
       18. A portable fuel cell power supply apparatus comprising an energy source, a fuel cell array consisting of at least one rechargeable fuel cell array sub-assembly having a plastic web comprising a patterned porous plastic substrate, electrolyte coating on the substrate, diffusion membrane, and gas manifolds for receiving fuel from the energy source, a thermal insulation and gas diffusion mat positioned on the fuel cell array, the gas diffusion mat having a water distribution matrix for removing and/or supplying water to the fuel cell array, a battery for receiving a continuous charge from the fuel cell array, and a holder for receiving the energy source, the fuel cell array, the diffusion mat and the battery. 
     
     
       19. The apparatus of claim  18 , wherein the energy source is a fuel tank. 
     
     
       20. The apparatus of claim  19 , wherein the fuel tank contains fuel that has a 1:1 molecular ratio of methanol to water. 
     
     
       21. The apparatus of claim  19 , wherein the fuel tank is refillable. 
     
     
       22. The apparatus of claim  18 , wherein the holder fits into the battery cavity of a cellular phone. 
     
     
       23. The apparatus of claim  18 , wherein the holder is of a plastic material. 
     
     
       24. The apparatus of claim  19 , further comprising a cavity in the holder for receiving the fuel tank. 
     
     
       25. The apparatus of claim  19 , further comprising a fuel level indicator window in the holder for viewing the level of fuel in the fuel tank. 
     
     
       26. The apparatus of claim  18 , wherein the diffusion mat has a thickness that varies across the fuel cell array. 
     
     
       27. The apparatus of claim  18 , further comprising a cover for covering the holder. 
     
     
       28. The apparatus of claim  21 , further comprising a refill port in the holder for adding fuel to the fuel tank. 
     
     
       29. The apparatus of claim  28 , further comprising a fuel dispenser for adding fuel to the fuel tank through the refill port. 
     
     
       30. The apparatus of claim  18 , wherein the fuel cell array is a surface replica fuel cell power source. 
     
     
       31. The apparatus of claim  21 , wherein the fuel tank is replaceable. 
     
     
       32. The apparatus of claim  31 , further comprising a kit having a plurality of fuel tanks for replacing spent fuel tanks.